Study of tribological performance of ECR-CVD diamond-like carbon coatings on steel substrates: Part 1. The effect of processing parameters and operating conditions

Diamond-like carbon (DLC) coatings were prepared on AISI 440C steel substrates at room temperature by electron cyclotron resonance chemical vapor deposition (ECR-CVD) process in C₂H₂/Ar plasma. Using the designed Ti/TiN/TiCN/TiC interfacial transition layers, relatively thick DLC coatings (1-2 μm) were successfully prepared on the steel substrates. The friction and wear performance of the DLC coatings was evaluated by ball-on-disk tribometry using a steel counterbody at various normal loads (1-10 N) and sliding speeds (2-15 cm/s). By optimizing the deposition parameters such as negative bias voltage, DLC coatings with hardness up to 30 GPa and friction coefficients lower than 0.15 against the 100Cr6 steel ball could be obtained. The friction coefficient was maintained for 100,000 cycles (∼2.2 km) of dry sliding in ambient environments. In addition, the specific wear rates of the coatings were found to be extremely low (∼10⁻⁸ mm³/Nm); at the same time, the ball wear rates were one order of magnitude lower. The influences of the processing parameters and the sliding conditions were determined, and the frictional behavior of the coatings was discussed. It has been found that higher normal loads or sliding speeds reduced the wear rates of the coatings. Therefore, it is feasible to prepare hard and highly adherent DLC coatings with low friction coefficient and low wear rate on engineering steel substrates by the ECR-CVD process. The excellent tribological performance of DLC coatings enables their industrial applications as wear-resistant solid lubricants on sliding parts.     

Tribological properties of Si-containing diamond-like carbon film under ATF lubricated condition

Recent years have seen a rise in social needs regarding safety and the environment, and this has placed increasing importance on product development for automotive parts that leads to smaller sizes, higher capacity, and lower costs. Diamond-like carbon (DLC) coating technology is being focused on as an effective solution to such issues.This paper reports on the tribological properties of a Si-containing diamond-like carbon film under an automatic transmission fluid (ATF) lubricated condition, which dramatically improves the performance of an electromagnetic clutch used in electronically controlled All-wheel-drive (AWD) coupling. The Si-containing DLC film maintains its rough sliding surface while simultaneously exhibiting extremely low aggression against mating materials. Thus, the boundary lubrication state of the initial friction stage is maintained, while also displaying a positive μ–v slope with excellent anti-shudder performance and a satisfactory friction coefficient as demanded by the drive train.Based on time-of-flight secondary ion mass spectrometry (TOF-SIMS) of sliding surfaces, it was speculated that the mechanism behind the good tribological properties of a sliding material coated with Si-containing DLC film under fluid lubrication are in part connected to the material properties of the DLC-Si film and an adsorbate such as a succinimide-based dispersant.     

Friction and wear properties of Fe7Mo6-based alloy in ethyl alcohol

In this study, the friction and wear properties of Fe₇Mo₆-based alloy, Fe and Mo disk specimens sliding against ASTM 52100 steel and Cu and SiC ball (or pin) specimens in ethyl alcohol were evaluated using an Optimol SRV oscillating friction and wear tester. The Fe₇Mo₆-based alloy disk specimens exhibited more stable friction coefficients than the Fe and Mo disk specimens when slid against the ASTM 52100 steel ball specimen. On the other hand, the Fe/SiC tribo-pairs exhibited the lowest average friction coefficients (0.14-0.17).     

Tribochemical interactions of Si-doped DLC film against steel in sliding contact

This study concerns the effects of tribochemical interactions at the interface of Si-DLC (silicon-doped diamond-like carbon) film and steel ball in sliding contact on tribological properties of the film. The Si-DLC film was over-coated on pure DLC coating by radio frequency plasma-assisted chemical vapor deposition (r.f. PACVD) with different Si concentration. Friction tests against steel ball using a reciprocating type tribotester were performed in ambient environment. X-Ray photoelectron spectroscopy (XPS) and auger electron spectroscopy (AES) were used to study the chemical characteristics and elemental composition of the films and mating balls after tests. Results showed a darkgray film consisting of carbon, oxygen and silicon on the worn steel ball surface with different thickness. On the contrary, such film was not observed on the surface of the ball slid against pure DLC coating. The oxidation of Si-DLC surface and steel ball was also found at particular regions of contact area. This demonstrates that tribochemical interactions occurred at the contact area of Si-DLC and steel ball during sliding to form a tribofilm (so called transfer film) on the ball specimen. While the pure DLC coating exhibited high coefficient of friction (∼0.06), the Si-DLC film showed a significant lower coefficient of friction (∼0.022) with the presence of tribofilm on mating ball surface. However, the Si-DLC film possesses a very high wear rate in comparison with the pure DLC. It was found that the tribochemical interactions strongly affected tribological properties of the Si-DLC film in sliding against steel.     

Tribochemical effects on the friction and wear behaviors of diamond-like carbon film under high relative humidity condition

Friction and wear behaviors of diamond-like carbon (DLC) film in humid N₂ (RH-100%) sliding against different counterpart ball (Si₃N₄ ball, Al₂O₃ ball and steel ball) were investigated. It was found that the friction and wear behaviors of DLC film were dependent on the friction-induced tribochemical interactions in the presence of the DLC film, water molecules and counterpart balls. When sliding against Si₃N₄ ball, a tribochemical film that mainly consisted of silica gel was formed on the worn surface due to the oxidation and hydrolysis of the Si₃N₄ ball, and resulted in the lowest friction coefficient and wear rate of the DLC film. The degradation of the DLC film catalyzed by Al₂O₃ ball caused the highest wear rate of DLC film when sliding against Al₂O₃ ball, while the tribochemical reactions between DLC film and steel ball led to the highest friction coefficient when sliding against steel ball.     

The critical condition for intrusion of a steel ball into sliding contact space

The intrusion tests of a ball into sliding contact space were carried out. A stainless steel ball with 3.175 mm radius was used as a sphere particle to study the critical intrusion condition of the ball into the contact space between the organic glass and the polyurethane rubber. The effect of intrusion angle of the contact space and the friction coefficients among the ball, the organic glass and the polyurethane rubber on the critical condition were studied experimentally. Then, the intrusion conditions for the ball into the contact space were analysed theoretically. The results showed that the calculated critical intrusion angles agreed well with the experimental ones. Finally, the intrusion diagram as a function of critical intrusion angle, friction coefficient µ₁ and µ₂ (here, µ₁ is the friction coefficient between the ball and the polyurethane rubber, µ₂ is the friction coefficient between the ball and the organic glass) was introduced to evaluate the intrusion performance of a ball into the sliding contact space. Copyright © 2010 John Wiley & Sons, Ltd.     

Frictional characteristics of ceramics under water‐lubricated conditions

Friction experiments were conducted on four kinds of ceramics (SiC, Si₃N₄, Al₂O₃ and ZrO₂) against themselves in water under different contact pressures and sliding velocities. The variations of friction coefficients as a function of sliding distance, and the effects of mean contact pressure and sliding velocity on friction coefficients were shown. Friction coefficients lower than 0.03 were observed under a certain combination of mean contact pressure and sliding velocity for each material. The friction coefficient suddenly increased when the mean contact pressure was above a threshold value, which depended on both sliding velocity and the material of sliding pairs. SiC had a higher threshold value than the other three ceramics at every sliding velocity investigated. This revised version was published online in June 2006 with corrections to the Cover Date.     

Tribological behaviour of steel‐alumina sliding pairs under boundary lubrication conditions

The tribological behaviour of oil‐lubricated steel‐alumina sliding pairs was investigated using a ball‐on‐disc tribometer at room temperature. Commercial bearing balls of 10 mm diameter were mated to 99.7% Al₂O₃ discs, and additive‐free mineral oil was fed into the contact area. The sliding speed and the applied normal load were varied, and the initial surface roughness of the Al₂O₃ disc was altered using different polishing and grinding procedures. The results showed that the surface roughness of the ceramic discs dominated the tribological behaviour under the given experimental conditions. The sliding speed as well as the normal load showed less effect on the friction behaviour, but the amount of wear depended strongly on the normal load. From the results it was concluded that improvement of the surface roughness and optimised surface machining of the ceramic material can be essential for improving the tribological performance for boundary‐lubricated steel‐ceramic sliding pairs.     

Influence of Surface Roughness on the Transfer Film Formation and Frictional Behavior of TiC/a-C Nanocomposite Coatings

Influence of surface roughness on the friction of TiC/a-C nanocomposite coatings while sliding against bearing steel balls in humid air was examined by detailed analyses of the wear surfaces and the wear scar on the ball counterparts by atomic force microscopy, optical, and confocal microscopy. It was observed that the surface roughness of the coatings essentially determines the wear behavior of the ball counterpart, which consequently influences the transfer film formation. A rough coating causes abrasive wear of the steel ball during the running-in period, which impedes the formation of a stable transfer film and leads to higher values of coefficient of friction (CoF). Moreover, the CoF does not show a decreasing trend after the running-in period, although the roughness of the coating was greatly reduced. Replacing the worn ball with a new one after the running-in period yields lower CoF values similar to that observed for a smooth coating. In both of the cases, no wear of the steel ball occurs and a stable transfer film forms and effectively covers the contact area. The influence of the wear debris on the formation of the transfer film is also discussed.     

Effects of Normal Load,Sliding Speed,and Surface Roughness on Tribological Properties of Niobium under Dry and Wet Conditions

The effects of normal load, sliding speed, and surface roughness on the friction and wear of high-purity niobium (Nb) during sliding without and with an introduction of water were systematically investigated. Increasing the normal load or sliding speed decreased the friction of the Nb under the both dry and wet conditions because the increased wear of the Nb decreased the interfacial shear strength between the steel ball and Nb by promoting the surface roughening and the production of wear debris. However, the Nb tested at the lowest sliding speed under the lowest normal load with water exhibited the lowest friction and wear due to the formation of oxide layer on the wear track. The friction and wear of the Nb tested under the dry condition decreased with increased surface roughness because the higher interfacial shear strength between the steel ball and smoother Nb resulted in the earlier breakdown of the native oxide layer and direct contact between the steel ball and Nb. However, increasing the surface roughness of the Nb increased its friction and wear under wet conditions, probably due to the easier breakdown of the oxide layer that formed on the rougher surface during sliding. The tribological results clearly showed that the introduction of water during sliding had a significant influence on the tribological properties of the Nb.     

Experimental determination of static and dynamic coefficients of sliding friction of epilam-coated materials

The effect of the method for depositing epilam coatings on materials on the static and dynamic coefficients of sliding friction is experimentally studied. Experiments were carried out using the pin-on-plate arrangement under dry friction conditions at a constant velocity of sliding under pressures of 0.5–5 MPa. It has been found that, for a like friction pair made from the 14Kh17N2 steel, the deposition of epilam coatings on materials reduces the coefficients of friction, but the wear resistance of the coated materials changes only slightly because the epilam film has a molecular-layer thickness. Thermovacuum tests carried out at T = 350°C under a pressure of 10^?6 Torr have shown the loss of the antifriction properties of the materials covered with the 6SFK-180-05 epilam.     

Experimental extrapolation model for friction and wear of polymers on different testing scales

The friction and wear behaviour for polyoxymethylene homopolymers (POM-H) and polyethylene terephthalate with teflon additives (PET/PTFE) is compared on small-scale cylinder-on-plate tests (50-200 N normal loads) and large-scale flat-on-flat tests (190-3880 kN normal loads). A common parameter to characterise tribological data is the contact pressure×sliding velocity (pv-value), but its use seems restricted to a single testing scale. Four experimental models are presented to extrapolate tribological data from one to another testing scale, based on (i) one single mechanical parameter (normal load or contact pressure), (ii) two mechanical parameters (normal load and sliding velocity), (iii) the contact pressure-sliding velocity model (pv-temperature limit), (iv) macroscopic geometry model. The latter model is most extensive, considering the influences of thermal effects (frictional heat generation and dissipation), sample geometry (geometry factor G) and visco-elastic contact (critical contact pressure p₀). For unfilled polymers, the introduction of macroscopic scaling factors allows for the extrapolation of coefficients of friction obtained on different testing scales. Specific or volumetric wear rates cannot be extrapolated because they strongly depend on the sample geometry, while linear wear rates are in better agreement when considering the transitions between mild wear, softening and melting. For internally lubricated polymers, extrapolation is more difficult. The differences depending on the testing scale are attributed to contact stress concentrations near the sample borders and limited wear debris mobility within large contact areas, promoting a homogeneous film formation onto the polymer surface.     

Stribeck Curve Under Friction of Copper Samples in the Steady Friction State

The friction and wear of a pure copper block (99.98 wt% Cu) against a hardened steel disc were studied. The effect of sliding velocity and load on the friction coefficient and wear rate of Cu samples during steady tests was studied. Elasto-hydrodynamic (EHL), mixed (ML) and boundary lubrication (BL) regions were analyzed using the Stribeck curve. The lubrication number of Schipper, Z, was used in the analysis of the Stribeck curve. The transitions from one lubrication region to another are discussed. The mixed EHL region is characterized by stable low values of the friction coefficient, wear rate and temperature. Straight asperity contact is the dominant mechanism under friction of Cu–steel pair in the BL region. High-friction coefficients and wear rates, thin lubricant films and large wear grooves indicate straight asperity contact between rubbed surfaces in the BL region. Although the dominant mechanisms in the mixed EHL and BL regions are different in principle, a steady friction state is preserved in both cases. It is expected that the steady friction state in the BL and mixed EHL regions is associated with deformation and fracture of surface layers but these process occur at different scale levels. It was shown that under friction of Cu–steel pair, two types of ML regions are observed. The first is the stable steady friction of mixed EHL with low values of the friction coefficient and wear rate. The second type of the ML region is the region of unstable friction and wear when a decrease of lubricant film leads to a change of external (roughness, temperature, friction and wear) and internal (strain and stress) parameters. It was found out that a transition to the unstable ML region occurs within a narrow range of Z parameter under definite values of the load and sliding velocity.     

The tribological properties of YBa2Cu3O7 films in ambient environment

In the present study, high-T_c superconducting thin YBa₂Cu₃O₇ films and polysilicon films were prepared to investigate the initial sliding friction properties using a ball-on-flat tribometer when samples were moved against a sapphire ball or a steel ball in ambient environment. The surface topography was measured with atomic force microscope (AFM). After five times testing, the experimental results indicate that the friction coefficient of YBa₂Cu₃O₇ films is lower than that of polysilicon films when sliding against a sapphire ball and almost the same when sliding against a steel ball. In particular, the initial friction of YBa₂Cu₃O₇ films is more stable when sliding against a sapphire ball. However, the initial friction of polysilicon films fluctuates during a cycle period when sliding against a sapphire ball. They are both stable when sliding against a steel ball. Although, the surface profile of the YBa₂Cu₃O₇ film is rough and can be seen to be rougher than the polysilicon film, but the friction coefficient of the YBa₂Cu₃O₇ film is lower than that of polysilicon film. Also, although the topography of YBa₂Cu₃O₇ films changes during friction, the friction coefficients are stable. This clearly shows that the initial sliding friction of YBa₂Cu₃O₇ films under microfriction is stable. The observation signifies YBCO film is a good film to prevent stick–slip motion in ambient environment. The wear properties of YBa₂Cu₃O₇ films suggest that the superconducting outgrowths (CuO) are loose and they can be easily removed.     

Effect of counter materials on coefficients of friction of TiN coatings with preferred grain orientations

In order to investigate the effect of counter materials on the coefficients of friction of TiN coatings with preferred grain orientations, the coefficients of friction against six counter materials (ball) were measured. The ball materials were aluminum (A1050), stainless steel (SUS304, SUS440C), bearing steel (SUJ2), carburized steel (SWRM10), cemented tungsten carbide (WC-Co) and alumina (Al₂O₃). After tests, the worn flat surfaces of balls and the wear tracks of TiN coatings were analyzed by the electron probe micro analysis (EPMA) and the auger electron spectroscopy (AES) to observe the Ti oxide film on each ball material and the adhesion of ball materials to the TiN coatings. The Ti oxide film was observed on the worn flat surfaces of the ball materials and the ball materials did not adhere to the TiN coatings in case that the low coefficients of friction were obtained.     

Tribological behavior between micro- and nano-crystalline diamond films under dry sliding and water lubrication

The tribological behavior of micro- and nano-crystalline diamond films is evaluated in dry sliding and water lubricating condition. The main wear mechanism is found to be abrasive wear mode induced by self-polishing. Non-diamond components and higher compressive residual stresses are detected in flat MCD films after dry sliding, in comparison to NCD. Origin of decreased friction coefficient in CVD diamond tribosystems under water lubrication is attributed to the effect of water on the formed graphic material and the chemisorbing of diamond surface with H₂O, hydrogen or hydroxyl ions. For the MCD/NCD or NCD/MCD contact, the surface roughness of ball largely determines the stable friction coefficient in dry sliding, where NCD film usually presents higher wear rate.     

Effect of transfer film structure, composition and bonding on the tribological behavior of polyphenylene sulfide filled with nano particles of TiO2, ZnO, CuO and SiC

The tribological behavior of polyphenylene sulfide (PPS) filled with inorganic nano particles was studied. The fillers investigated were TiO₂, ZnO, CuO and SiC whose sizes varied from 30 to 50 nm. The polymer composites were compression molded with varying proportions of these fillers. Wear and friction tests were performed in a pin-on-disk configuration at a sliding speed of 1.0 m/s, nominal pressure of 0.65 MPa, and counterface roughness of 0.10 μm Ra. The polymer composite pins slid against hardened tool steel counterfaces. The transfer films of the composite materials formed on the counterfaces during sliding were studied by optical microscopy and X-ray photoelectron spectroscopy (XPS) and the adhesion between the transfer film and counterface was measured in terms of the peel strength. It was found that the wear rate of PPS decreased when TiO₂ and CuO were used as the fillers but increased with ZnO and SiC fillers. The optimum wear resistance was obtained with 2 vol.% CuO or TiO₂. These filled composites had the coefficients of friction lower than that of the unfilled PPS. The wear behavior of the composites is explained in terms of the topography of transfer film and adhesion of transfer film to the counterface as observed from peel strength studies. There is a good correlation observed between the transfer film-counterface bond strength and wear resistance.     

Characteristics of the Friction Between Aluminium and Steel at Elevated Temperatures During Ball-on-Disc Tests

Appropriate specification of the frictional boundary condition for the finite-element (FE) simulation of metal-forming processes is of great importance to the trustworthiness of the results. The research reported in this communication aimed at understanding the interfacial contact between aluminium and steel at elevated temperatures and determining friction coefficients at this material mating. A series of high-temperature ball-on-disc tests were carried out with the AA7475 aluminium alloy as the material of disc and the hardened H11 steel as the material of ball. A mathematical model developed in the preceding research was employed to account for the evolution of the contact interface during ball-on-disc tests. Friction coefficients at different temperatures and over a number of laps were determined. The shear friction stresses and mean contact pressures along with the progress of the tests at 350–500 °C were calculated. It was found that the friction coefficients obtained from ball-on-disc tests alone were insufficient to represent the frictional interaction between deforming aluminium and steel at elevated temperatures. The evolution of the contact interface with increasing sliding distance must be taken into consideration and the friction behaviour can be reasonably characterized by using friction stress.     

Large-scale friction and wear tests on a hybrid UHMWPE-pad/primer coating combination used as bearing element in an extremely high-loaded ball-joint

The surfaces of a heavily loaded ball-joint were initially covered with a sliding spray and suffer wear. A solution is found by incorporating UHMWPE pads (Ultra high molecular weight polyethylene) with a carbon fibre/epoxy reinforced ring as sliding material into the chairs of the structure, while the steel ball-side is covered with a Zn-phosphate primer coating, protecting against corrosion. The local static and dynamic behaviour of the hybrid UHMWPE pads in contact with steel or Zn-coated counterfaces has been large-scale tested on loading capacity, low friction and wear resistance. For protection of the sliding counterface against wear, a polymer lip covering the carbon ring has been experimentally designed to flow over the carbon ring under high contact pressures, assuming the retained polymer disc under hydrostatic conditions. As such, the soft coating resists extremely high contact pressures (150 MPa) with good adhesion to the steel ball. However the application method should be carefully selected, sprayed coatings are the most favourable for low initial static friction. Calculated bulk and flashtemperatures revealed that the UHMWPE melting temperature is not exceeded, although softening of the coating under high contact pressures may be favourable for a ‘self-repairing’ ability. Pre-sliding creep and intermediate wear paths as manifesting in the ball-joint were simulated, indicating that the maximum design coefficient of friction is not exceeded. Test results are compared to FEM-calculations to verify the practical applicability of the modified sliding system.     

Stable and super‐low friction of amorphous carbon nitride coatings in nitrogen gas by using two‐step ball‐on‐disk friction test

Effect of running‐in process on friction behaviour of carbon nitride (CNx) coating in N₂ gas stream was investigated with a newly introduced two‐step ball‐on‐disk friction test, where the rubbed Si₃N₄ ball in the pre‐sliding (step 1) was replaced by a new CNx‐coated Si₃N₄ ball in the subsequent sliding stage under N₂ gas (step 2). The two‐step friction test is clarified to be a simple but effective technique for obtaining contact material combination of self‐mated CNx coatings and for achieving stable and low frictions of CNx coatings. Friction coefficients of CNx/CNx in N₂ gas stream decrease greatly from 0.07 without pre‐sliding to less than 0.025 in two‐step friction tests. The minimum friction coefficient of 0.004 was obtained by introducing 500 cycles of pre‐sliding in ambient air. These stable and low frictions are attributed to the generation of self‐mated CNx coatings and the formation of a lubricious layer on the disk surface. Copyright © 2014 John Wiley & Sons, Ltd.